Filter assemblies utilizing full cross-section

Abstract

A filter assembly comprises a filter housing defining an internal volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and a sidewall. A filter element is disposed within the internal volume. The filter element comprises a filter media pack at least a portion of which has an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the internal volume of the filter housing. A support structure is coupled to at least one longitudinal end of the filter media pack.

What is claimed is: 
     
         1 . A filter assembly, comprising:
 a filter housing defining an internal volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and a sidewall;   a filter element disposed within the internal volume, the filter element comprising:
 a filter media pack, at least a portion of the first filter media pack having an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the internal volume of the filter housing; and 
 a support structure coupled to at least one longitudinal end of the filter media pack. 
   
     
     
         2 . The filter assembly of  claim 1 , wherein the support structure is coupled to a longitudinal end of the filter media pack at which a fluid exits the filter media pack after passing therethrough. 
     
     
         3 . The filter assembly of  claim 1 , wherein the support structure includes:
 a first support structure coupled to a first longitudinal end of the filter media pack distal from the base; and   a second support structure coupled to a second longitudinal end of the filter media pack opposite the first longitudinal end.   
     
     
         4 . The filter assembly of  claim 1 , wherein the filter media pack comprises a tetrahedral media. 
     
     
         5 . The filter assembly of  claim 4 , wherein an outer cross-section of the filter media pack is circular. 
     
     
         6 . The filter assembly of  claim 1 , wherein the filter media pack comprises an axial flow filter media pack structured to allow a fluid to flow therethrough along a longitudinal axis of the filter assembly. 
     
     
         7 . The filter assembly of  claim 3 , wherein each of the first support structure and the second support structure comprise a grid or mesh. 
     
     
         8 . The filter assembly of  claim 2 , wherein a sealing member is disposed between the filter element proximate to a longitudinal end of the filter media pack opposite the longitudinal end at which the support structure is disposed, and the sidewall of the filter housing so as to prevent fluid from flowing around the filter media pack. 
     
     
         9 . The filter assembly of  claim 3 , wherein the filter housing further comprises an outlet chamber formed between the second support structure and the base, and wherein an outlet is provided in the outlet chamber to allow filtered fluid to exit the filter housing. 
     
     
         10 . The filter assembly of  claim 9 , further comprising a cap coupled to an end of the filter housing distal from the base, an inlet defined in the cap so as to allow fluid to enter the filter housing. 
     
     
         11 . The filter assembly of  claim 1 , wherein the filter media pack is formed from a filter media comprising:
 a filter media layer folded along a folding axis thereof such that a first edge of the filter media layer is proximate to an opposite edge of the filter media layer after being folded and a filter pocket is formed by the filter media layer, the filter pocket configured to receive unfiltered fluid; and   an influent flow mesh disposed in the filter pocket.   
     
     
         12 . The filter assembly of  claim 11 , wherein the filter media layer is bonded to at least itself or the influent flow mesh along the folding axis. 
     
     
         13 . The filter assembly of  claim 11 , wherein the filter media further comprises an effluent flow mesh disposed on a surface of the filter media layer outside the filter pocket. 
     
     
         14 . The filter assembly of  claim 13 , wherein the filter media pack comprises a cylindrical roll of the filter media layer rolled along its folding axis. 
     
     
         15 . The filter assembly of  claim 13 , wherein the filter media pack comprises a plurality of filter media layers providing plurality of filter pockets, each of the plurality of filter pocket having an effluent flow mesh disposed therebetween. 
     
     
         16 . The filter assembly of  claim 1 , further comprising an upstream filter media disposed upstream of the filter element. 
     
     
         17 . A filter assembly, comprising:
 a filter housing defining an internal volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and a sidewall;   a filter element disposed within the internal volume, the filter element comprising:
 an axial flow filter media pack, a channel defined through the axial flow filter media pack along a longitudinal axis of the filter assembly, the axial flow filter media pack configured to allow a fluid to flow therethrough along the longitudinal axis in a first direction and be filtered, the filtered fluid flowing through the channel in a second direction opposite the first direction towards the outlet, at least a portion of the axial flow filter media pack having an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the internal volume of the housing; and 
 a support structure coupled to at least one end of the axial flow filter media pack. 
   
     
     
         18 . The filter assembly of  claim 17 , wherein the support structure is coupled to an end of the axial flow filter media pack at which a fluid exits the axial filter media pack after passing therethrough. 
     
     
         19 . The filter assembly of  claim 17 , wherein the support structure comprises:
 a first support structure coupled to a first end of the axial flow filter media pack; and   a second support structure coupled to a second end of the axial flow filter media pack opposite the first end.   
     
     
         20 . The filter assembly of  claim 17 , wherein the outer cross-sectional distance of the axial flow filter media pack comprises a sum of (a) a cross-sectional width of the channel; (b) a first radial distance from an inner surface of the axial flow filter media pack forming the channel at a first location to an outer surface of the axial flow filter media pack proximate to the first location; and (c) a second radial distance from the inner surface of the axial flow filter media pack at a second location opposite the first location, to the outer surface of the axial flow filter media pack proximate to the second location. 
     
     
         21 . The filter assembly of  claim 17 , wherein the axial flow filter media pack comprises a tetrahedral media. 
     
     
         22 . The filter assembly of  claim 21 , wherein the outer cross-section of the axial flow filter media pack is circular. 
     
     
         23 . The filter assembly of  claim 17 , wherein the filter element further comprises a center tube positioned within the channel, an end of the center tube coupled to the outlet. 
     
     
         24 . The filter assembly of  claim 19 , further comprising a cap coupled to an end of the filter housing opposite the base such that an inlet chamber is defined between the first support structure and the cap, the base located at a lower elevation relative to the cap, the cap defining the outlet of the filter housing and an inlet for allowing the fluid to enter the inlet chamber, the outlet fluidly sealed from the inlet chamber,
 wherein a flow reversal chamber is defined between the second support structure and the base, the filtered fluid changing a flow direction thereof from the first direction towards the second direction in the flow reversal chamber.   
     
     
         25 . The filter assembly of  claim 24 , further comprising a drain provided in the flow reversal chamber for draining liquid collected in the flow reversal chamber. 
     
     
         26 . The filter assembly of  claim 24 , wherein the first support structure and the second support structure comprise a grid or mesh. 
     
     
         27 . The filter assembly of  claim 18 , wherein a sealing member is disposed between the first support structure and the sidewall of the filter housing so as to prevent fluid from flowing around the axial flow filter media pack. 
     
     
         28 . The filter assembly of  claim 19 , further comprising a cap is coupled to an end of the filter housing opposite the base such that an inlet chamber is defined between the second support structure and the cap, the cap located at a lower elevation relative to the base, the cap defining an inlet for allowing the fluid to enter the inlet chamber, and the outlet, the outlet fluidly sealed from the inlet chamber,
 wherein a flow reversal chamber is defined between the first support structure and the base, the filtered fluid changing a flow direction thereof from the first direction towards the second direction in the flow reversal chamber.   
     
     
         29 . The filter assembly of  claim 28 , further comprising a drain provided in the inlet chamber for draining liquid collected in the inlet chamber. 
     
     
         30 . The filter assembly of  claim 28 , wherein the first support structure and the second support structure comprise a grid or mesh. 
     
     
         31 . The filter assembly of  claim 28 , wherein a sealing member is disposed between the second support structure and the sidewall of the filter housing so as to prevent fluid from flowing around the filter media. 
     
     
         32 . The filter assembly of  claim 17 , wherein the axial flow filter media pack is formed from a filter media comprising:
 a filter media layer folded along a folding axis thereof such that a first edge of the filter media layer is proximate to an opposite edge of the filter media layer after being folded and a filter pocket is formed by the filter media layer, the filter pocket configured to receive unfiltered fluid; and   an influent flow mesh disposed in the filter pocket.   
     
     
         33 . The filter assembly of  claim 32 , wherein the filter media layer is bonded to at least itself or the influent flow mesh along the folding axis. 
     
     
         34 . The filter assembly of  claim 32 , wherein the axial flow filter media pack further comprises an effluent flow mesh disposed on a surface of the filter media layer outside the filter pocket. 
     
     
         35 . The filter assembly of  claim 34 , wherein the axial flow filter media pack comprises a cylindrical roll of the filter media layer rolled along its folding axis. 
     
     
         36 . A filter element configured to be disposed within a filter housing having an inner cross-section that defines a maximum inner cross-sectional distance, the filter element comprising:
 a filter media pack, at least a portion of the first filter media pack having an outer cross-section defining a maximum outer cross-sectional distance that is substantially equal to the maximum inner cross-sectional distance of the filter housing; and   a support structure coupled to at least one longitudinal end of the filter media pack distal.   
     
     
         37 . A filter element configured to be disposed within a filter housing having an inner cross-section defining an inner cross-sectional distance, the filter element comprising:
 an axial flow filter media pack, a channel defined through the axial flow filter media pack along a longitudinal axis of the filter element, the axial flow filter media pack configured to allow a fluid to flow therethrough along the longitudinal axis in a first direction and be filtered, the filtered fluid flowing through the channel in a second direction opposite the first direction towards the outlet, at least a portion of the axial flow filter media pack having an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the housing; and   a support structure coupled to at least one end of the axial flow filter media pack.